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FCA US LLC CEP-12679
Corporate Engineering Publication Date Published: 2018-07-31
Change Level: D Total No. of Pages (Including Annex): 10
Contact: Brian Funtik
Phone: 248 576 4065 / 776 4065

CLASSIFICATION OF CHARACTERISTICS

Foreword

The purpose of this standard is to define and classify the technical characteristics that may exist in
component parts and systems.

Characteristics may require validation with variable or attribute data. Examples of characteristics include
(but are not limited to) part dimensions, material properties, torque, correct part usage, and weld
integrity.

Product quality and reliability are impacted by design, process specifications, inspection cycles,
selection of process equipment, and personnel training. The classification of characteristics and the
characteristics themselves are one of the tools which can help correctly perform the above-mentioned
activities, with the goal of ensuring world class quality.

Changes

Scope expanded to include ePT high voltage battery systems and power electronics.
Referenced standards and procedures updated.
Other
Capability requirements for datum freestate and prequalification updated.
Annex A added.

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Table of Contents
1 SCOPE ...................................................................................................................................................... 3
2 REFERENCES .......................................................................................................................................... 3
3 ABBREVIATIONS, ACRONYMS, DEFINITIONS, & SYMBOLS .............................................................. 3
4 REGULATED SUBSTANCES AND RECYCLABILITY ............................................................................. 3
5 OVERVIEW ............................................................................................................................................... 3
5.1 Rationale for Classifications ................................................................................................................... 3
5.2 Use of Classifications ............................................................................................................................. 4
5.3 Roles and Responsibilities ..................................................................................................................... 4
6 CLASSIFICATIONS .................................................................................................................................. 5
6.1 Regulatory Characteristics ..................................................................................................................... 6
6.2 Critical Characteristics ........................................................................................................................... 6
6.3 Capability Characteristics....................................................................................................................... 7
6.4 Ordinary Characteristics......................................................................................................................... 7
7 STATISTICAL PROCESS CONTROL ...................................................................................................... 7
8 ACCEPTANCE CRITERIA ........................................................................................................................ 8
Annex A ......................................................................................................................................................... 9

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1 SCOPE
This standard applies to body, exterior, interior, chassis, restraints, electrical, and engine systems
components and assemblies released for the NAFTA region. It does not apply to Powertrain Engineering
with the exception of ePT high voltage battery systems and power electronics.

2 REFERENCES

Table 1 - References
downloadable
Shield/Desi
for suppliers
Document Number gnator (if Document Title from
applicable)
beSTandard
CEP-12542 CMM Feature Measurement Standards
PF-HOMOLOGATION Product Homologation
PF-EMISSIONS E Identification of Emissions Items
PF-SAFETY S Product Safety Use of Safety Shields
PS-7300 D Product Quality Use of Diamonds
PS.50004/01 S WELDING - RESISTANCE SPOT
QR-10005 Measurement Systems Analysis (MSA) 4th Edition
QR-10012 DIMENSIONAL QUALITY REQUIREMENTS
QR-10016 Statistical Process Control (SPC) - 2nd Edition
QR-10018 Potential Failure Mode & Effects Analysis (4th Edition)
SD-12690 Dimensional Verification Program Point Selection Rules
SQ.00010 Advance Quality Planning (AQP) & Production Part Approval Process (PPAP)
TCAE System and CAD Part Management Within the Scope of
07226
Product/Process Development
CS.00118 FCA Gage Standard
PRO.A0583 NAFTA Part Inspection Standard Process

3 ABBREVIATIONS, ACRONYMS, DEFINITIONS, & SYMBOLS

CMM. An acronym for Coordinate Measurement Machine.
DQP. An acronym for Dimensional Qualification Process.
PIP. An acronym for Part Information Page.
PA. An acronym for Process Audit.
PQP. An acronym for Part Qualification Process.
SPC. An acronym for Statistical Process Control.

4 REGULATED SUBSTANCES AND RECYCLABILITY

Not applicable.

5 OVERVIEW

5.1 Rationale for Classifications

Each product or process characteristic is classified on the basis of the following factors, which are listed in
order of priority:

- Presence of legal requirements (homologation, emissions, or safety).

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- The consequences from which any departure from engineering specifications (e.g. nominal values,
tolerances) could have on the product or assembly for which the product is intended.

- The likelihood that such consequences will follow (e.g. the design margins of safety).

- The likelihood that such a departure from specifications will occur (e.g. the ease with which the
characteristic is produced by normal processes).

5.2 Use of Classifications

Characteristic classifications are intended to aid manufacturing decision making in the following ways:

- Provides guidance (together with tolerances) in selecting an appropriate manufacturing process.

- Aids logistics planning, because it highlights particular product requirements (legal compliance,
traceability, record keeping, etc.).

- It defines the sampling, reporting, and acceptance criteria.

The classification does not dictate the means by which variable or attribute data is to be collected.

5.3 Roles and Responsibilities

5.3.1 Internal Designed Parts Identification of Characteristics

The cross functional dimensional team (engineering and manufacturing) is responsible for selection and
classification of characteristics.

5.3.2 Co-Designed Parts Identification of Characteristics

The design-responsible supplier is responsible for selection and classification of characteristics. The
product engineering, dimensional, and manufacturing team is required to approve the characteristics.

Each design-responsible supplier is required to facilitate a meeting to obtain GD&T and measurement
plan approval for each CAD release.

The FCA product engineer is responsible for the proper CAD release in TeamCenter per FCA standard
07226.

5.3.3 Assembly a Identification of Characteristics

Selection and documentation of characteristics is led by the ME-Control Plan team and is approved by
the Stamping Technology Quality team and Body Design Tolerancing.

5.3.4 Data Collection and Reporting

The part producer should adhere to the Part Inspection Standard, which is available in the source
package per PRO.A0583. Unless otherwise specified, identification of the specific data collection method
(for example, CMM, scan, variable gage) is the responsibility of the part producer and is documented in
the control plan.

The part manufacturing source is responsible for metrology system set-up, fixtures, gages and associated
metrology equipment, inspection and data reporting. Fixtures and gages must adhere to FCA gage
standard CS.00118.

If a point based data collection system (for example, CMM) has been chosen to evaluate characteristics,
the manufacturing source is responsible for all programming.

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The Advanced Metrology Group (AMG) will provide:

- Complete running CMM programs for BIW assemblies.

- Ordered Buy parts. Critical parts are identified by the ME-

Dimensional team.

-
plants only during the die development phase (for example, at METD and external die shops).
Critical parts are identified by the ME-Dimensional team.

parts, the part producer is responsible for measurement system programming. The part
producer is also responsible to ensure data can be uploaded to the FCA US LLC eCMM database and to
upload data upon request and as required by QR-10012. See also QR-10012 for additional information
regarding data upload requirements and procedures.

CMM feature names must adhere to FCA US LLC standard CEP-12542.

The part producer may choose to define statistical process control (SPC) point locations and to use SPC
methods. See Section 7 for more information regarding SPC.

For each characteristic, the part manufacturing source is also responsible to furnish attribute or variable
data in a format that is acceptable to the FCA US LLC team.

6 CLASSIFICATIONS
Each characteristic of a part or system is classified as shown in the following sections. See Table 2 for a
summary chart.

For information related to the classification of resistance spot welds, refer to PS.50004/01<S>.

Characteristics and the associated classification must be documented in the appropriate engineering
drawing, CAD model, PIP, process sheet, or control plan. In addition, characteristics may also be
summarized in the Part Inspection Standard as per PRO.A0583.

Figure 1 - Associated Classification

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Table 2 - Classification Summary chart

Description Type Requirements Symbol
Regulatory characteristics have an impact on the
<S>
safety or emissions performance of the vehicle or
REGULATORY See applicable standard <E>
are expected to be important for vehicle
<H>
homologation.
Deviation from the required specifications of critical Ongoing demonstration of
characteristics may compromise the efficiency or CRITICAL capability and ongoing data
use of the product by the customer. reporting required. NOTE 1
Deviation from the required specification of
capability characteristics may cause potential
problems with efficiency, use, or vehicle assembly. Proved to be capable during Part
CAPABILITY
These characteristics are used primarily to Quality Assessment process.
establish product capability and to aid root cause
analysis.
Features affecting the function of the part. Proved to meet specifications
ORDINARY
during Part Quality Assessment -
CHARACTERISTICS
process.

NOTE 1: See Table 3 for capability requirements for datum freestate and prequalification characteristics.

6.1 Regulatory Characteristics

Regulatory characteristics have an impact on the safety or emissions performance of the vehicle or are
expected to be important for vehicle homologation. These characteristics will be designed with <S>, <E>,
or <H>.

Requirements are documented in PF-HOMOLOGATION, PF-SAFETY<S>, and PF-EMISSIONS<E>.

6.2 Critical Characteristics

Deviation from the required specifications of critical characteristics may compromise the efficiency or use
of the product by the customer. These characteristics are indicated by a diamond or traffic light symbol in
the engineering drawing, PIP, process sheets, or control plan.

The traffic light point symbol is shown in Figure 2.

Figure 2 - Traffic Light Symbol

Critical characteristics may also be used for process monitoring. See QR-10016 for more information on
statistical process control methods and Section 8 of this standard. However, classification of a
critical
require the use of SPC. The control plan (or equivalent document) governs the specific measurement
method and inspection frequency.

Critical characteristics are initially evaluated during Part Quality Assessments (see Section 8) as a subset
of the capability characteristics and must be monitored and reported during the entire product life cycle.

If a critical characteristic is related to part dimensions, variable data is required.

Critical characteristics associated with datum freestate or prequalification do not require demonstration of
process capability. Instead, these characteristics are required to be in tolerance and the part producer is
required to report average and range on an ongoing basis.
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For diamond characteristics, see PS-7300<D>.

6.3 Capability Characteristics

Deviation from the required specification of capability characteristics may cause potential problems with
efficiency, use, or vehicle assembly. These characteristics are used primarily to establish product
capability and to aid root cause analysis.

Variable data is generally required for capability characteristics.

Capability characteristics are evaluated during Part Quality Assessments (see Section 8) and must be re-
evaluated and reported upon request from FCA US. It is not a requirement to continuously monitor and
report capability characteristics (exception: capability points that are used to establish critical relationships
must be continuously monitored but not reported).

The part supplier should take steps to ensure, and should have confidence, that these characteristics will
remain statistically capable to the product requirements.

The capability characteristic symbol is shown in Figure 3.

Figure 3 - Capability Characteristic Symbol

6.4 Ordinary Characteristics

The requirements for these characteristics are documented with feature control frames in the engineering
drawing, as a default requirement from an engineering standard or drawing, or as requirements in the PIP
or on the face of the drawing, but do not have any special modifier or shield.

Dimensional characteristics of this type shall be validated with a long dimensional validation program,
with photogrammetry or scanning technology, or by other means that is acceptable to FCA US.

Specific CMM point locations will not be documented in the CAD model. If CMM verification is to be used,
CMM point creation and CMM programming is the responsibility of the part supplier. FCA US LLC CMM
point labels are required. See SD-12690.

These characteristics are evaluated during Part Quality Assessments (see Section 8) and must be re-
evaluated and reported upon request from FCA. It is not a requirement to continuously monitor and
report these characteristics. However, the part supplier should take steps to ensure and should have
confidence that these characteristics respect the product requirements.

7 STATISTICAL PROCESS CONTROL

Whenever possible, SPC locations should be co-incident with regulatory, critical or capability
characteristics. SPC points that are not co-incident with these characteristics are intended solely for
process monitoring and are not subject to other requirements set forth in this document.

SPC point locations may be documented with a note in the engineering drawing. See Figure 4.

When used in conjunction with the classifications as described in section 6 of this document, features
monitored with SPC may also carry specific additional requirements (for example, variable data collection

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in the checking gage) beyond those described above. These additional specific requirements must be
specified in the relevant Part Inspection Standard document.

Figure 4 - Example Of SPC Location Documentation

See QR-10016 for more information on statistical process control methods.

8 ACCEPTANCE CRITERIA
See Table 3 for the acceptance criteria for each type of characteristic.

Table 3 - Acceptance Criteria

Type Symbol Pp/PpK Target Cp/CpK Target
<S>
REGULATORY <E> 2.00 2.00
<H>
67 ACCEPTABLE
CRITICAL 33 MAY REQUIRE IMPROVEMENT
NOTE 1 NOTE 1

CAPABILITY
ORDINARY - IN TOLERANCE IN TOLERANCE

NOTE 1: Critical characteristics associated with datum freestate and prequalification are only required to be in tolerance.

End of Main Document

#####

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Annex A
Informative
METHODOLOGY FOR CHARACTERISTICS CLASSIFICATION SELECTION
This section contains an explanation of one engineering methodology which can be used to select the
appropriate characteristic classification for each technical characteristic of a product design.

Variation is inherent in any manufacturing and or assembly process. Knowledge of the magnitude and
consequences of this variation will help engineers properly design and classify product characteristics in
order to meet customer requirements and to aid in the design of manufacturing processes. Before
classification can be completed, two factors must be considered: the design margin impact of the
characteristic and the FMEA effect severity.

A.1 Design Margin Impact

The design margin impact is defined as the loss or degradation of product function resulting from process
variation.
PFMEA manual (reference QR-10018).

Three levels of design margin impact are possible:

Table A-1 - Design Margin Impact Definition

DESIGN
OCCURRENCE
MARGIN DEFINITION
RATING
IMPACT
Very little margin exists between the expected process variation and the
technical specifications and the slope of the loss function curve is high;
HIGH 6 and greater
therefore, strict control of the characteristic is required. High probability
of loss of function if process is not capable.
Some margin exists between the expected process variation and the
technical specifications and/or moderate loss function curve slope;
MEDIUM 4-5
therefore, moderate control of the characteristic is required. Medium
probability of loss of function if process is not capable.
Large margin exists between the expected process variation and the
technical specifications and/or low loss function curve slope; therefore,
LOW 1-3
ordinary control of the characteristic is required. Low probability of loss
of function if process is not capable.

The loss function and anticipated process variation can be represented by curves or by discrete point
values derived from theoretical analysis (for example, tolerance chain analysis, a 3D tolerance model, or
Finite Element Method) or by available knowledge such as design standards, carry over part
performance, returns from the field, or experimental tests.

A.2 FMEA Effect Severity

Severity is the value associated with the most serious effect for a given failure mode. Severity is a
relative ranking within the scope of the individual FMEA.

See table Cr1 in QR-10018 for suggested FMEA severity criteria. Rank 1 indicates that the potential
failure is not expected to have an effect. Rank 10 indicates that the potential failure affects safe vehicle
operation without warning.

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A.3 Classification Selection

The following steps ensure a correct and objective classification:

1. Functional analysis of the system, from the function expected by the customer to the technical
elementary function
2. Evaluation of effect severity perceived by customer in case of loss of function (see section A.2)
3. Evaluation of the design margin impact (see section A.1)
4. Failure mode root causes identification
5. Correlation of root causes to design specifications
6. Evaluation of characteristic impact on the function under study
7. Definition of the classification according to the Table A-2.

See also QR-10018 for a deeper explanation of the FMEA methodology.

Table A-2 - Classification Table

Design Margin Impact

High Medium Low

Regulatory Regulatory Regulatory

NOTE 1 NOTE 1 NOTE 1
9-10
Regulatory Ordinary

7-8 Ordinary

5-6 Ordinary Ordinary

1-4 Ordinary Ordinary Ordinary

NOTE 1: For functions assessed with FMEA effect severity 9 or 10, any associated characteristics subject to legislatively-mandated
These include emissions, safety,
or any other regional government or regional standard requirements.

End of Annex A

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